Construction of gliding board and method of production

ABSTRACT

A gilding board, which means of the kinds of sporting or leisure boards for sliding on waters, snow and land, was constructed by polyethylene foam material, in three-ply or above layers of constant density or different densities as its multi-layer of bard core, agglutinate with a layer of plastic polymer graphic film on one side of the board core and bonded with high tenacity of plastic protective board on the other side. The essence of the gliding board is its particular methodology of production by mechanically adhibiting instant injection of high temperature of compound thermoplastic substance on the surface of the first layer of the board core while bonding with a layer of plastic graphic film. Thereafter, cleaving a plastic protective board or polyethylene foaming skin with the third layer of board core, by adopting heat lamination method to viscose the second layer of board core with both graphic film layer plus plastic protective board layer, in which an outer core of media foam layer is being exempted between the graphic film layer and board core, and the plastic polymer protective board to board core, as a result of simplify the production process in making the board, less resources and material to be consumed during the production that leads environmental-friendly, reducing cost to be involved in production, but provides a great performance and substantially deep-set of the structure of the board. Three-ply board core enhances the greater crash-worthiness from water surfing, snow or land gliding, with provision of better comfort and a function of high security for users by smooth surface of board on both ends.

FIELD OF THE INVENTION

This invention is related to gliding board, particularly means of allkinds of gliding devices for sporting and leisure purposes. The devicescan be identified as surfboards, bodyboards, wakeboards, swimboards,kickboards, snow sleds, skimboards, grass-gliders, sand-gliders, etc.The unique production methods and multi-layers of board core give theadvantages of simplification the manufacturing process, minimise theconsumption of resources and material in production, reducingmanufacturing cost, provides a better architecture of the board itselftogether with enhancing its steadfast of the board core for providingbetter safety and comfort performance for end-users.

BACKGROUND OF THE INVENTION

Generally, a gliding board is applied as a surfing board on waters whichis formed by a single layer of polymer foam material with opened celland low density or double layers with different densities, laminatedtogether for performance of an inner board core, in which the boarditself wrapped by crosslinked or non-crosslinked polyethylene by heatlamination, in between an outer board core of single layer of highdensity, closed-cell foam material performed as an essential media layerto bond to both sides of board core by heat lamination, to forming thesurf boards.

Similar as surfing boards, another type of sports boards which normallyused as a snow slider, usually composed of dual-layer with low densityof polymer foam material as board core and essentially having a higherdensity, closed-cell foam material as media layer for better bonding, byheat laminating between the top and bottom sides of board core and topand bottom skin of the boards. Normally, the boards have hand railsapparatus and shaped the board as upward curve for speed acceleration.

Typically the bonding of plastic graphic film, in general the thicknesswould be between 1 mil to 5 mils, with one or above layers of plasticpolymer film for covering the graphic artwork inside, should havelaminated to no less than one layer of media backing foam or backingsheet, with thickness around 2 mils to 6 mils, and with higher densityaround 6 pounds PCI, for adherence to the polyethylene foam board coreof sports boards by heat lamination and to protect the graphic imprint,in which augment the complexity and difficulty of production process andmuch resources to be expended and being not cost efficiency andeffectiveness.

The impulsion of the cleave lamination between plastic protective boardand the board core was the mezzanine plastic backing foam layer withhigher density, normally this layer was in range of 2 mils to 6 mils inthickness and 6 pounds PCI in density. Being the resistance ofpolyethylene foam material involved the limitation of boding method,thereof, such sport boards were usually being made by this method.

SUMMARY OF THE INVENTION

The concernment of the invention to the gliding boards is thearchitecture of the three-ply board core in which omitted the two layersof outer core. The structure of the polyethylene board core isconfigured by four different ways of combination of triplex polyethylenefoam material. First, the three-ply board core is configured by threelayers of same density and thickness, preferably in range of 3 to 6pounds PCI with thickness between 2 mils and 18 mils, or at the samedensity with different thickness. Further, it is applicable by adoptinga different density with the same thickness or different thicknesseither; preferably the top two layers of the board core would be havingthe same higher density than the bottom layer. Density of both top twolayers will be in a range of 3 to 6 pounds PCI with thickness at around2 mils to 15 mils, to comparison with the bottom layer of board core,which have lower density at a range of 1 to 4 pounds PCI with thicknessaround 10 mils to 20 mils. The remarkable improvement over the existingcongeneric sports boards was the structure of the polyethylene boardcore enabled for directly agglutinating, without the aid of outer coreof backing foam or backing sheet, to the top plastic polymer graphic.film and the bottom plastic polymer protective board mechanically. Byapplying of this methodology, both two layers of backing foam or backingsheet on both ends of board core will be omitted as a result of costsaving on resources consumption and production cost would be minimized,and to be more environmental-friendly.

The improved methodology of bonding the plastic polymer graphic film tothe polyethylene board core was made by adopting a layer of compoundthermoplastic substance, a newly refined material for supersede thetraditional bonding method of heat lamination. The compound substanceconsists of low density polyethylene, tackifying resin and ethylenevinyl acetate copolymer, to be furnaced with high temperature of 180 to200 degree, thereafter, to be mechanically injected on the surface ofthe first layer of polyethylene board core. Generally, the thickness ofthe thin plastic polymer graphic film is under the range of 0.01 mil to0.5 mil and the side with reverse graphic artwork imprinted will beadhesively cleaving, by the compound thermoplastic substance,approximately 0.1 to 0.8 mil in thickness, to the side of board core.Furthermore, in which the surface with graphic imprinted will be wellprotected against the frictions from extrinsic impacts. Being theair-cell from the board core have been filled up by the compoundthermoplastic substance thereby the integration of the plastic polymergraphic film with the polyethylene board core will be adhesivelyagglutinated. To ensue a better performance of tenacity of the bothlayers, a pair or rollers will be applied while the injection mode hasbeen performed in between the surface of the polyethylene board core andthe plastic polymer graphic film, in which a top roller consists ofpattern on its surface and the plain roller at the bottom will bepressurized on the graphic film to board core for a better interlock forthe prevention of the graphic film to be tear-off from the board core,and with the provision of a greater smooth graphic skin of the gildingboards.

The other invention to the gliding boards is the production process ofthe adhesion of plastic polymer protective board to polyethylene boardcore. Traditionally, from prior generic bonding method of the protectiveboard to board core, there would be a media layer, a mezzanineclosed-cell, high density of polyethylene backing foam or backing sheet,which thickness was approximately 2 mils to 6 mils, would be adhered byheat lamination method to the board core for further easier bonding withthe protective board. The present invention is to omit the function ofthe mezzanine polyethylene backing foam as media, but to directlyagglutinate the board core with the plastic polymer protective board byadopting the new methodology of dual-layer of thermoplastic polymersubstance as the way for replacement of heat lamination of board corewith backing foam to plastic protective board. It is a new inventedmethod that separately applying two furnaces with high temperaturearound 180 to 200 degree for melting the polymer substance. These twoadhesive elements are either low density polyethylene or high densitypolyethylene. These two layers of thermoplastic polymer substance willbe injected simultaneously with same pace, on one side of the thirdboard core. Thickness of the first layer of polymer substance will be inrange of 0.1 mil to 0.5 mil and the second layer will be in range of 2mils to 5 mils. The function of the first layer is to fill in the aircells on the surface of polyethylene board core by the polymer substanceto enhance the stiff of the board core. Thereafter, the second layer ofpolymer substance is to agglutinate both board core with plastic polymerprotective board, in which the thickness is around 0.2 mil to 0.8 mil,to perform a better bonding for the gliding boards. This method is toviscose the board core with plastic polymer protective board in a bettercondition that not easily for tearing from frictions and conclusion, andbonding without the aid of backing foam or backing sheet, but to bedirectly agglutinated, not by generic hot lamination, as a result ofless production process will be made, cost saving on resourcesconsumption and much eco-friendly to the earth.

Another invention on the polyethylene board core is applying threelayers of polyethylene foam as the core of the gliding board. Thisimproved core design is to provide a better function of board core as acushion itself, to alleviate the impacts and hurtle from gliding inspeed and to perform a better protection for users. Generally, fromprior art boards, the structure of the boards were made of one layer ortwo layers of polyethylene foam, with lower density, approximately attwo pounds PCI with 10 mils to 15 mils foam board as board's inner core,thereafter laminated with one layer of closed-cell but high density ofpolyethylene foam sheet, approximately at six pounds PCI with 2 mils to6 mils thickness, by heat lamination method to bonding the outer core onboth sides of the inner core, to form as an outer core for the functionof protection of the inner core and further heat lamination with plasticpolymer protective board and plastic polymer skin at the top. However,by means of one or two layers of inner board core was not effective foralleviation of impulse from waters and snow while gliding. Therefore,the present invention is to enhance the structure of the board core intothree layers, in which the first two layers will have the same higherdensity than the bottom layers, to intensity the cushiony function ofthe polyethylene foam core. Normally the density will be around 3 to 6pounds PCI with 2 mils to 15 mils in thickness. The bottom layer is toalleviate the impulse of the friction while gliding on land, waters orsnow and to sustain the pressure from the users when lying or sitting onthe top of the board gliding. Normally this layer of foam core will belower density but in same thickness as in second layer of board core,approximately at round 1 to 4 pounds PCI with thickness at around 10mils to 20 mils.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a cross-sectional view of a prior art sports board structure.

FIG. 2 is a cross-sectional view of new invention gliding boardstructure with same density on the first two layers of board core.

FIG. 3 is a cross-sectional view of new invention gliding boardstructure with different density on the first two layers of board core.

FIG. 4 is a perspective view of nineth embodiment of the gliding board.

FIG. 5 is a partially schematic view of the new methodology of bondingof plastic polymer graphic film to polyethylene board core of theinvention.

FIG. 6 is a partially schematic view of the new methodology of viscoseof polyethylene board core of the invention.

FIG. 7 is a partially schematic view of the method of manufacturing ofgliding board of the invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1 shows that a structure of a prior art sports board 13, the innerboard core is formed by heat lamination of 13 and 14, a lower density,closed-cell polyethylene foam material, thereon, 12 the outer core ofbacking foam board sheet, with higher density and closed-cell foam, heatlaminated to 13 for further heat lamination of the surfaces to 11, theplastic polymer graphic film 15, a layer of backing foam sheet, by heatlamination to 15 as a media laminate with 16, the plastic polymerprotective board

FIG. 2 shows a cross-sectional view of the structure of the invention inwhich three layers of polyethylene board core are in same thickness orin same density. Adopting the compound thermoplastic substance 18 foragglutination with 17 the plastic polymer graphic film to 19 first layerboard core with high density with closed-cell polyethylene foammaterial, thereafter, 22 a dual-layer of thermoplastic polymer substanceagglutinated with 23 the plastic polymer protective board to 21 thirdlayer of polyethylene board core, a lower density with closed-cellpolyethylene foam material, therewith, by heat lamination method forbonding 20 a same density, closed-celled polyethylene foam material as19 to 21, pre-shaped thereafter by heat lamination with 19, 17 theplastic polymer graphic film extending from the top portion to theplastic protective board at the bottom and formed the gliding board.

FIG. 3 shows a similar cross-sectional view of the structure of theinvention as at FIG. 2, but in which three layers of polyethylene boardcore are in different thickness or density. Adopting the compoundthermoplastic substance 25 for agglutination with 24 the plastic polymergraphic film to 26 first layer board core with high density withclosed-cell polyethylene foam material, thereafter, 29 a dual-layer ofthermoplastic polymer substance agglutinated with 30 the plastic polymerprotective board to 28 third layer of polyethylene board core, a lowerdensity with closed-cell polyethylene foam material, therewith, by heatlamination method for bonding 27 a same density, closed-celledpolyethylene foam material as 26 to 28, pre-shaped thereafter by heatlaminating with 26, 24 the plastic polymer graphic film extending fromthe top portion to the plastic protective board at the bottom and formedthe gliding board.

FIG. 4 shows a perspective view of nineth embodiment of the presentinvention of a gliding board consists of a plastic polymer graphic film32 at the top with graphic imprint inside 34 and pattern on the surface31, by agglutination of compound thermoplastic substance 33 to the firstlayer of polyethylene board core 35 and by heat lamination to the secondlayer of polyethylene board core 36 and third layer of polyethyleneboard core 37. Thereto, with aid of a dual-layer of thermoplasticpolymer substance 38 for cleave agglutinate with 39 the plastic polymerprotective board. Finally, the top plastic polymer graphic filmextending from the top portion to the plastic protective board at thebottom and formed the gliding board.

FIG. 5 shows a schematic view of the new methodology of bonding ofplastic polymer graphic film to polyethylene board core of theinvention. By shoving the compound thermoplastic substance whichcontains low density polyethylene, tackifying resin and ethylene vinylacetate copolymer in the 40 furnace with high temperature of 180 to 200degree, thereafter, going through the T-die for injection a layer ofcompound thermoplastic substance in between of 41 plastic graphic filmand 44 first layer of polyethylene board core which are both in rollformat and to be bonded and pressurized by 42 the upper pattern rollerand 43 a lower plain roller for reinforcement of the stiffness of thegraphic film to board core.

FIG. 6 shows a schematic view of the new methodology of viscose of thepolyethylene board core of the invention. By shoving either low densitypolyethylene or high density polyethylene into both 45 and 46 furnacewith high temperature of 180 to 200 degree, thereafter, going throughthe T-die for injection a dual-layer of thermoplastic substance on thesurface of 49 third layer of polyethylene board core which is exportedfrom roll format and to be bonded and pressurized by 47 the upper rollerand 48 a lower roller for reinforcement of the stiffness of the boardcore for replacement of the backing foam sheet laminated to the boardcore for further heat lamination of plastic polymer protective board.

FIG. 7 is a schematic view of the method of manufacturing of glidingboard of the invention. By applying heat lamination method through 51the febrifacient and pushing through the pair of roller forpressurizing, to bonding either 50 the plastic polymer protective boardand 53 third layer of polyethylene board core, or 50 the second layer ofpolyethylene board core to 53 the third layer of polyethylene board corewith plastic polymer protective board, or 50 the first layerpolyethylene board core bonded with plastic polymer graphic film to 53the pre-shaped second plus third polyethylene board core bonded withplastic polymer protective board. Thereafter, behind the rollers, pressthe materials for having a curve shape at the front of the board, and 52is the semi-product of the gliding board and will be processedafterwards by further heat lamination to extending the graphic film fromtop to the bottom of plastic polymer protective board to form thegliding board.

The foregoing description should be considered as illustrative only ofthe principles of the invention. Since numerous modifications andchanges will be readily occur to those skilled in the art, it is notdesired to limit the invention to the exact construction and operationshown and described, and, accordingly, all suitable modifications andequivalents, including the composition by means of the number of layers,the densities of the materials and the thickness of each layers, may beresorted to, falling within the scope of the invention.

1. A gliding board comprising a top plastic polymer graphic film, abottom plastic polymer protective board, and a three-ply polyethyleneboard core located between the top plastic polymer graphic film and thebottom plastic polymer protective board, the three-ply polyethyleneboard core including closed-cell, polymer foam material.
 2. The glidingboard as claimed in claim 1, wherein the top plastic polymer graphicfilm has a thickness of between 0.01 mil to 0.5 mil, with a reversegraphic imprint on one side.
 3. The gliding board as claimed in claim 1,wherein a lamination between the top plastic polymer graphic film and afirst layer of the three-ply polyethylene board core is agglutinated bya compound thermoplastic substance, the compound thermoplastic substanceincludes a mixture of low density polyethylene, tackifying resin andethylene vinyl acetate copolymer having a thickness of approximately 0.1to 0.8 mil.
 4. The gliding board as claimed in claim 1, wherein a firstlayer of the three-ply polyethylene board core includes closed-cell foammaterial having a density in a range of 3 to 6 pounds PCI with athickness of 2 mils to 15 mils.
 5. The gliding board as claimed in claim4, wherein a second layer of the three-ply polyethylene board coreincludes closed-cell foam material having a density in a range of 3 to 6pounds PCI with a thickness of approximately 2 mils to 15 mils.
 6. Thegliding board as claimed in claim 5, wherein a third layer of thethree-ply polyethylene board core includes closed-cell foam materialhaving a density in a range of 1 to 6 pounds PCI with a thickness ofapproximately 10 mils to 20 mils.
 7. The gliding board as claimed inclaim 1, wherein a thickness of the three-ply polyethylene board core isapproximately 2 mils to 20 mils.
 8. The gliding board as claimed inclaim 1, wherein a density of the three-ply polyethylene board core isapproximately 1 to 6 pounds PCI.
 9. The gliding board as claimed inclaim 1, wherein the bottom plastic polymer protective board has athickness of approximately 0.2 mils to 0.8 mils.
 10. The gliding boardas claimed in claim 1, wherein a lamination between the bottom plasticpolymer protective board with a third layer of the three-plypolyethylene board core is achieved by a dual-layer of thermoplasticsubstance for cleave agglutination.
 11. The gliding board as claimed inclaim 10, wherein a thickness of a bottom layer of the dual-layer ofthermoplastic substance is 0.1 mil to 0.5 mil and a top layer of thedual-layer of thermoplastic substance is in a range of 2 mils to 5 mils.12. The gliding board as claimed in claim 11, wherein the dual-layerthermoplastic substance consists of one of high density polyethylene andlow density polyethylene.
 13. The gliding board as claimed in claim 1,wherein the top plastic polymer graphic film extends to attach to thebottom plastic polymer protective board. 14-20. (canceled)